Field-assembled air conveyance apparatus, and systems and methods utilizing air conveyance apparatus

ABSTRACT

An air conditioning system includes an air handler, an evaporator coil, a blower and a heater all within the air handler. The system further includes an air filter and a transition between the air handler and the air filter. The transition includes at least four panels that together define a perimeter and an interior of the transition. A first end of the transition is configured to be attached to the air handler. A second end of the transition is opposite the first end, and an air filter is disposed at the second end. At least one of the at least four panels includes an access door that opens to allow access into the interior of the transition. A method includes positioning the first end of the transition at a first end of the air handler, and positioning the air filter at the second end of the transition.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 17/643,226 filed on Dec. 8, 2021, having a title of“Field-Assembled Air Conveyance Apparatus, Systems and Methods”. Thecontents of the prior application are hereby incorporated by referenceherein in their entirety.

TECHNICAL FIELD

The present disclosure relates generally to heating, ventilating and/orair conditioning (HVAC) systems and, more particularly, tofield-assembled air conveyance apparatuses, such as field-assembled HVACsheet metal transitions, and systems and methods utilizing airconveyance apparatuses.

BACKGROUND

When installing a cased air conditioning evaporator coil on the top, orother outlet, of a high Seasonal Energy Efficiency Ratio (SEER) furnacethe inlet dimensions of the coil, may not be the same dimensions as theoutlet of the furnace. In most cases the outlet of the furnace issmaller than the inlet of the coil and a reduction in air flow iscreated such that SEER ratings are not achieved. Furthermore, prescribedservicing of aforementioned appliances are restricted and in some casesnot achievable, thus requiring a full disassembly/separation of theappliances to gain access to needed internal components.

Transitions, or the like, used to join an air handling unit, such as afurnace, and another unit, such as the aforementioned air conditioningevaporator coil, are formed from sheet metal in an off-site shop andtransported to a job site. Shipping or other transport of such anopen-ended transition, or the like, is problematic in that it is bulkyand structurally unsound, alone. For example, it is often necessary tomount the transition on a palette which greatly increases shipping ortransportation costs.

One of the more important factors that affect efficiency of an HVACsystem is static pressure. Static pressure can be defined as theresistance to airflow within the ductwork in an HVAC system and in anelectric air-handler or heat-pump and other components. For an HVACsystem to operate efficiently, air must be pushed through the air ductswith greater intensity than the static pressure level within the system.If the HVAC system does not meet this condition, airflow can beadversely restricted. Thus, the lower the static pressure, the betterthe efficiency.

SUMMARY

In general, a static pressure of 0.5 inches per water column (in. W.C.)or lower is ideal. A static pressure greater than 0.5 in. W.C. canresult in several problems. For example, the restricted airflow causedby a larger static pressure can result in noisy heating and coolingequipment. The higher the static pressure, the louder the noise in theHVAC system will be. In addition, impaired airflow can result inundesirable hot spots, cold spots, or air that hovers above a register.This is because when static pressure is high, the HVAC system tends tomove too much air, or an insufficient amount of, air per ton. Moreover,the inefficiency caused by high static pressures can place undue strainon the compressor, the blower motor, and/or other components of the HVACsystem, because the system must work harder to compensate for poorairflow. The undue strain can lead to premature equipment failure andhence expensive repairs. Of course, inefficiency can also increase theamount of energy needed to run the HVAC system, resulting in higherelectricity bills. Finally, high static pressures may also adverselyaffect the refrigerant when charging the unit, and may cause air filtersto load up with particulates faster than normal.

HVAC systems may use one or more air filters to remove impurities suchas dust, pet dander or even bacteria from the air flowing through thesystem. Conventionally, an air filter has been positioned in an HVACsystem at a location abutting the base of the electric air handlingunit. In that location, the air filter is close to or adjacent theevaporator coil in the air handling unit. This position of the airfilter relative to the evaporator coil increases the static pressure inthe HVAC system. This is especially true when the dimensions of the airfilter are greater than the dimensions of the inlet of the air handler,e.g., when the perimeter of the filter is greater than the perimeter ofthe inlet. The differences in size create an offset between the airfilter and the air handler which results in restricted air flow and thusmore static pressure.

The inventors of the present invention have determined that placing atransition between the air filter and the electric air handler cangreatly reduce or eliminate the static pressure that would otherwiseexist without the transition. The transition can provide enough distancebetween the air filter and the evaporator coil to maximize airflowentering the base of the air handler without a restriction. Further, thetransition can be sized to the dimensions of the air handler and/or theair filter so that airflow between the air handler and the air filtercan be maximized and the static pressure minimized. Conversely, the airfilter can be sized to match the dimensions of the transition. Inaddition, providing the transition with a removable access panel or doorcan allow for cleaning/inspection of the evaporator coil and/or airfilter without having to disassemble the components of the HVAC system.

The present invention is directed to systems and methods which provide aheating, ventilation and air conditioning (HVAC) air conveyanceapparatus that can reduce or eliminate static pressure in an HVAC systemwhile providing easy access for cleaning and/or inspection of theevaporator coil and/or air filter without having to disassemble thecomponents of the HVAC system.

In accordance with some aspects, an air conditioning system comprises:an air handler; an evaporator coil in the air handler; a blower in theair handler; a heater in the air handler; an air filter; and atransition between the air handler and the air filter.

In accordance with some aspects, the air conditioning system furthercomprises: an air return unit on one side of the air filter.

In accordance with some aspects, the transition comprises a panel thatincludes an access door that opens to allow access into an interior ofthe transition.

In accordance with some aspects, a length of the transition is at least8 inches so that the air filter is at least 8 inches away from the airhandler.

In accordance with some aspects, the transition includes a panelcomprising one or more access ports opening into the interior of thetransition.

In accordance with some aspects, the air conditioning system furthercomprises: an ultraviolet light mounted within the transition; and abaffle on the ultraviolet light, wherein the baffle is positioned toface the air filter to protect the air filter from being degraded byultraviolet light.

In accordance with further aspects, a transition for an air conditioningsystem comprises: at least four panels that together define a perimeterof the transition and an interior of the transition; a first endconfigured to be attached to an air handler; a second end opposite thefirst end; and an air filter at the second end, wherein at least one ofthe at least four panels includes an access door that opens to allowaccess into the interior of the transition.

In accordance with some further aspects, a length of the transition fromthe first end to the second end is at least 8 inches.

In accordance with some further aspects, at least one of the at leastfour panels includes one or more access ports opening into the interiorof the transition.

In accordance with some further aspects, the at least four panels areconfigured to be detachably attached to each other to allow thetransition to be field assembled at a job site.

In accordance with some further aspects, at least one of the at leastfour panels includes a mounting port for mounting an ultraviolet lightand baffle within the interior of the transition.

Also, in accordance with some aspects, a method of transitioning withinan air conditioning system comprises: positioning a first opened end ofa transition at a first opened end of an air handler comprising anevaporator coil, a blower, and a heater; and positioning a first side ofan air filter at a second opened end of the transition, the secondopened end being opposite the first opened end of the transition.

In accordance with some aspects, the method further comprises:positioning an opened end of an air return unit on a second side of theair filter, the second side being opposite the first side.

In accordance with some aspects, the method further comprises: providinga panel of the transition with an access door that opens to allow accessinto an interior of the transition.

In accordance with some aspects, the air filter is positioned at thesecond opened end of the transition to be at least 8 inches away fromthe air handler.

In accordance with some aspects, the method further comprises: providinga panel of the transition with one or more access ports opening into theinterior of the transition.

In accordance with some aspects, the method further comprises: mountingan ultraviolet light within the transition, wherein a baffle ispositioned on the ultraviolet light to face the air filter to protectthe air filter from being degraded by ultraviolet light.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used to limit the scope of the claimed subject matter.

The foregoing has outlined rather broadly the features and technicaladvantages of the present invention in order that the detaileddescription of the invention that follows may be better understood.Additional features and advantages of the invention will be describedhereinafter which form the subject of the claims of the invention. Itshould be appreciated that the conception and specific embodimentdisclosed may be readily utilized as a basis for modifying or designingother structures for carrying out the same purposes of the presentinvention. It should also be realized that such equivalent constructionsdo not depart from the invention as set forth in the appended claims.The novel features which are believed to be characteristic of theinvention, both as to its organization and method of operation, togetherwith further objects and advantages will be better understood from thefollowing description when considered in connection with theaccompanying figures. It is to be expressly understood, however, thateach of the figures is provided for the purpose of illustration anddescription only and is not intended as a definition of the limits ofthe present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 is a front side perspective view of an example of a combinedcomponent field-assembled sheet metal heating, ventilation and airconditioning (HVAC) air conveyance apparatus, according to someembodiments;

FIG. 2 is an opposite, rear side perspective view of the examplecombined component field-assembled sheet metal HVAC air conveyanceapparatus of FIG. 1 , according to some embodiments;

FIG. 3 is a partially exploded perspective view of a combined componentfield-assembled sheet metal HVAC air conveyance apparatus, according tosome embodiments;

FIG. 4 is a perspective view of an example solid end component panel fora field-assembled sheet metal HVAC air conveyance apparatus, accordingto some embodiments;

FIG. 5 is a perspective view of an example doored end component panelfor a field-assembled sheet metal HVAC air conveyance apparatus,according to some embodiments;

FIG. 6 is a perspective view of an example side component panel for afield-assembled sheet metal HVAC air conveyance apparatus, according tosome embodiments;

FIG. 7 is an enlarged perspective view of an example hemmed cleatemployed in the panels of FIGS. 1 thorough 6, according to someembodiments;

FIG. 8 is a further enlarged end view of an example hemmed cleatemployed in the panels of FIGS. 1 thorough 6, according to someembodiments;

FIG. 9 is perspective view of the example doored end component panel ofFIG. 5 , one example side component panel of FIG. 6 , the example solidend component panel, of FIG. 4 and another example side component panelof FIG. 6 stacked, according to some embodiments:

FIG. 10 is perspective view of the example doored end component panel ofFIG. 5 , two example side component panels of FIG. 6 and the examplesolid end component panel, of FIG. 4 and stacked, according to someembodiments;

FIG. 11 is flowchart of a process for field-assembly of a sheet metalHVAC air conveyance apparatus, according to some embodiments; and

FIG. 12 is a perspective diagrammatic view of a HVAC system employing anembodiment of the present field-assembled sheet metal air conveyanceapparatus, according to some embodiments.

FIG. 13 is a side perspective view of a heating, ventilation and airconditioning (HVAC) system including an air conveyance apparatus,according to some embodiments.

FIG. 14A is an exploded perspective view of an ultraviolet light andbaffle assembly that may be included in the heating, ventilation and airconditioning (HVAC) system, according to some embodiments.

FIG. 14B is a perspective view of the baffle side of the assembledultraviolet light and baffle assembly, according to some embodiments.

FIG. 14C is a perspective view of the ultraviolet light side of theassembled ultraviolet light and baffle assembly, according to someembodiments.

FIG. 15 is a side perspective view of a heating, ventilation and airconditioning (HVAC) system including another air conveyance apparatus,according to some embodiments.

FIG. 16 is a diagrammatic view of a method of transitioning within anHVAC system employing an air conveyance apparatus, according to someembodiments.

While this specification provides several embodiments and illustrativedrawings, a person of ordinary skill in the art will recognize that thepresent specification is not limited only to the embodiments or drawingsdescribed. It should be understood that the drawings and detaileddescription are not intended to limit the specification to theparticular form disclosed, but, on the contrary, the intention is tocover all modifications, equivalents and alternatives falling within thespirit and scope of the claims. Also, any headings used herein are fororganizational purposes only and are not intended to limit the scope ofthe description. As used herein, the word “may” is meant to convey apermissive sense (i.e., meaning “having the potential to”), rather thana mandatory sense (i.e., meaning “must”). Similarly, the words“include,” “including,” and “includes” mean “including, but not limitedto.”

DETAILED DESCRIPTION

The invention now will be described more fully hereinafter withreference to the accompanying drawings. This invention may, however, beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein. Rather, these embodiments areprovided so that this disclosure will be thorough and complete, and willfully convey the scope of the invention to those skilled in the art. Oneskilled in the art may be able to use the various embodiments of theinvention.

As noted, one of the challenges that heating, ventilating and/or airconditioning (HVAC) contractors are faced with when installing a casedcoil on the top, or at the outlet, of a high Seasonal Energy EfficiencyRatio (SEER) furnace is that the inlet dimensions of the coil, are notthe same dimensions as the outlet of the furnace. Similar problems arisewhen the inlet of the furnace is installed at the outlet of the coil.Either such installation may use a transition, or the like disposedbetween the units. In most cases the outlet of the furnace is smallerthan the inlet of the coil and a reduction in air flow is created suchthat SEER ratings are not achieved or compromised, and thus, totalsystem efficiency is hampered, distribution of thermal dynamicproperties are compromised and designed or intended heat transfer andflow distributions characteristics are compromised. Transitions may alsobe used in laboratories, to connect testing ductwork or instrumentationto various types of air handlers, heating units, cooling units, or thelike.

Embodiments herein relate generally to HVAC systems and, moreparticularly, to field-assembled air conveyance apparatuses, such asfield-assembled HVAC sheet metal transitions, and systems and methodsrelated thereto. Herein, embodiments of a field-assembled (insulated)sheet metal to field-assembled air conveyance apparatus, such as a sheetmetal transition that is adapted to be install in between the outlet ofa furnace (or other forced air hander) and a cased air conditioningevaporation coil, are disclosed.

In accordance with embodiments of the present field-assembled(insulated) sheet metal air conveyance apparatus systems and methods, aplurality of panels are adapted to be field-assembled to form the airconveyance apparatus. These panels may include a pair of firstquadrilateral panels, each defining a right-angle flange extending fromeach of a pair of opposite edges and a pair of second quadrilateralpanels, each defining a hemmed cleat along each of a pair of oppositeedges. Each hemmed cleat is shaped and dimensioned to receive one of thefirst quadrilateral panel right-angle flanges to form the air conveyanceapparatus. Also, HVAC unit mating flanges may extend from each otheredge of each of the first quadrilateral panels and/or from each otheredge of each of the second quadrilateral panels, such that at least apair of opposed peripheral HVAC unit mating flanges extend from each endof the HVAC air conveyance apparatus.

Embodiments of the present field-assembled (insulated) sheet metal airconveyance apparatus are a knockdown multi-panel unit, which is adaptedto be packaged, transported, and dispatched in a minimized footprintconfiguration. Embodiments of the unit utilize a series of flange andhem fasteners, such that the unit can be field-assembled at the site ofthe application, utilizing minimal tools. The panels used in accordancewith the present systems and methods are sized for many configurationsfor various application conformity.

The panel walls can be secured in place using a series of fittedmaterial bends that allow one flange to be inserted into an adjacentpanel's open hem. Furthermore, a (single) securing screw can lock thepanels together. In various embodiments, the unit includes a fibrousinsulation, which when coupled with the application appliance, improvessound-deadening properties. R-value properties, resistance to moistureand biology, and fire safety. After assembly, the double open-ended airconveyance apparatus can be placed between “inappropriately” sized and“non-conforming” air systems (i.e., cased oils, furnaces or other airhandlers that that have different dimensioned outlet and in inletopenings, as duct transitions, in laboratory air handling testingapplication configurations, or the like).

FIG. 1 is a front side perspective view of example combined componentfield-assembled sheet metal air conveyance apparatus (e.g., atransition) 100, and FIG. 2 is an opposite, rear side perspective viewof example combined component field-assembled sheet metal air conveyanceapparatus 100, according to some embodiments. FIG. 3 is a partiallyexploded perspective view of combined component field-assembled sheetmetal HVAC air conveyance apparatus 100, according to some embodiments.Combined component field-assembled sheet metal air conveyance apparatus100 includes solid end component panel 102, which in illustratedembodiment 100 forms the back (i.e., serves as the rear panel) of thecombined component field-assembled sheet metal air conveyance apparatus.FIG. 4 is a perspective view of example solid end component panel 102,according to some embodiments. Doored end component panel 104 forms afront of field-assembled sheet metal air conveyance apparatus 100. FIG.5 is a perspective view of example doored end component panel 104,according to some embodiments. In other embodiments, a combinedcomponent field-assembled sheet metal air conveyance apparatus maycomprise two solid end component panels 102, rather than one each ofsolid end component panel 102 and doored end component panel 104.

Regardless, the combined component field-assembled sheet metal airconveyance apparatus, such as illustrated combined componentfield-assembled sheet metal air conveyance apparatus (e.g., atransition) 100, also includes two, opposite side component panels 106.FIG. 6 is a perspective view of example side component panel 106 forfield-assembled sheet metal air conveyance apparatus 100, according tosome embodiments. Side component panels 106 may be symmetrical, such asillustrated in FIGS. 1, 2 and 5 , and thereby interchangeable forfield-assembly of a sheet metal air conveyance apparatus in accordancewith embodiments of the present systems and methods. However, in otherembodiments under the present systems and methods, side component panelsmay not be symmetrical, for example side panels that are asymmetricalmay be “dimensionally reflective” such that corresponding edges arealigned. As discussed in greater detail below, embodiments of thepresent field-assembled sheet metal air conveyance apparatus may makeuse of hemmed cleats 108. FIG. 7 is an enlarged perspective view ofexample hemmed cleat 108 employed in the panels of FIGS. 1 thorough 5,and FIG. 8 is a further enlarged end view of example hemmed 108,according to some embodiments. The hemmed cleat accepts any properlysized flange within the opening and then is able to be secured with afastener to hold the two panels together.

Thus, with attention directed to FIGS. 1 through 7 , an embodiment ofHVAC air conveyance apparatus (e.g., a transition) 100 may include aplurality of each of panels 102 and 106, but in some embodiments one ofeach side panel 102 and 104 and two of end panels 106.

Regardless, panels 102, 104 and 106 are adapted to be field-assembled toform HVAC air conveyance apparatus (e.g., a transition) 100. Each panelmay be formed out of sheet metal, such as galvanized steel, aluminum,stainless steel, powder coated steel, pre-painted steel, otheriron-carbon alloy combination, or the like, or may be formed out ofother materials such as a plastic or other polymer. In some embodiments,air conveyance apparatus 100 may be assembled using, by way of example,only four fasteners.

The plurality of panels includes a pair of first quadrilateral panels,end panels 102 and 104. In accordance with various embodiments, eachfirst quadrilateral (end) panel 102 or defines a right-angle (i.e.,generally 90 degree) flange 110 a through 110 d extending, generallyinward, as illustrated in FIGS. 3 and 4 , from each of a pair ofopposite edges 112 a through 112 d. Each of end panels 102 and 104 mayalso define HVAC unit mating flanges 114 a through 114 d extending fromeach other edge 116 a through 116 d of each first quadrilateral (end)panel 102 and 104, respectively. As shown in FIG. 5 , at least one ofthe panels making up air conveyance apparatus (e.g., a transition) 100may have an HVAC component access door 118. For example. FIG. 5 showsend panel 104 with HVAC component access door 118. Retaining latches120, as shown in FIG. 5 , or other mechanisms, may be used to removablysecure door 118 (closed) on panel 104. For example, as discussed ingreater detail below door 118 may be fastened to (peripherical) doorframe 122 of panel 104 by means of latches 120. Latches 120 may swivelabout a concentric point (on the (insulated) door) with a predeterminedrotational degree of freedom.

The aforementioned plurality of panels making up HVAC air conveyanceapparatus (e.g., a transition) 100 also includes a pair of secondquadrilateral panels, side panels 106. As best seen in FIG. 6 , eachsecond quadrilateral (side) panel 106 defines hemmed cleat 108 a or 108b along each of a pair of opposite edges 124 a and 124 b. While notshown in FIGS. 1 through 7 , side panels 106 may also define HVAC unitmating flanges, similar to HVAC mating flanges 114 of end panels 102 and104, extending from each other edge 126 a and 126 b of each secondquadrilateral (side) panel. Each hemmed cleat 108 is shaped anddimensioned to snuggly (e.g., within a functional snug fit tolerance)receive one of the first quadrilateral panel right-angle flanges 110 toform HVAC air conveyance apparatus 100, with peripheral HVAC unit matingflanges 114 extending from each end of assembled HVAC air conveyanceapparatus 100, as best seen in FIGS. 1 and 2 .

With attention directed to FIGS. 6 and 7 , each hemmed cleat 108 has, inaccordance with various embodiments, hem butt end 128 extendinggenerally perpendicular from face 130 of the respective secondquadrilateral (side) panel 106, and along and spaced apart from,respective edge 124 of the second quadrilateral (side) panel. Theintegral hemmed cleat 108 further defines projecting lip 132 extendingfrom hem butt end 128, generally parallel to face 130 of the respectivesecond quadrilateral (side) panel, toward respective edge 124, andspaced apart from face 130 a distance to define hemmed cleat slot 134.Open hem thickness slot 134 is sized to snug fit receive firstquadrilateral (end) panel right-angle flange 110. Each of hemmed cleats108 may has screw receptive hole 136 defined through projecting lip 132.Screw receptive hole 136 may be pilot hole, sized to receive fastener138 to secure first quadrilateral panel right-angle flange 110 receivedin hemmed cleat slot 134 in the hemmed cleat slot, to form HVAC airconveyance apparatus (e.g., a transition) 100. Correspondingly, in someembodiments, each first quadrilateral (end) panel right-angle flange 110may have a smaller right-angle flange screw receptive pilot hole 140defined through the right-angle flange. This right-angle flange screwreceptive pilot hole is spaced along right-angle flange 110 to alignwith screw receptive pilot hole 136 defined through projecting lip 132of hemmed cleat 108 when the right-angle flange is received in hemmedcleat slot 134 defined by the projecting lip. Further, smallerright-angle flange screw receptive pilot hole 140 may be sized (smallerthan hemmed cleat screw receptive pilot hole 136) to threadably receivefastener 138 to form HVAC air conveyance apparatus 100. In suchembodiments fastener 138 may be a self-threading, self-tapping,self-drilling, or similar screw, or the like. However, in otherembodiments, right-angle flange 110 may not define a screw receptivepilot hole, and in such embodiments the fastener may be a drill screw,which may be disposed through hemmed cleat screw receptive pilot hole136 defined through projecting lip 132 and drill-screwed intoright-angle flange 110 to form HVAC air conveyance apparatus 100.

Returning to FIGS. 1 through 5 , as noted each panel of the plurality ofpanels 102, 104 and 106 may, in accordance with embodiments of thepresent systems and methods, be generally quadrilateral in shape. Somepanels may further be trapezoidal in shape. For example, each edge 124of the pair of opposite edges of each second quadrilateral (side) panelare illustrated as trapezoidal legs for the respective panel. Also,correspondingly, each of other edge 126 of each second quadrilateralside panel are illustrated as trapezoidal bases for each respectivepanel. In various embodiments each such trapezoidal panel may generallyhave an isosceles trapezoidal shape. That is, where base angles have thesame measure, the two legs, edge pairs 124 a and 124 b are of equallength and each respective panel has reflection symmetry. In someembodiments some or all of the panels may be rectangular (or square) inshape.

As shown in FIGS. 1 through 5 , (rigid) insulation (panels) 142, such ascertified insulation panels, or the like, may be disposed (e.g.,secured, glued, compression fit, pinched, wedged via application offlange after having inserted the insulation, cupped head (weld) pinned,and/or the like) on an inner surface of each panel 102, 104 and 106 ofthe plurality of panels forming HVAC air conveyance apparatus (e.g., atransition) 100, including, in some embodiments (not shown) on an innersurface of door 118. The insulation panels may have a pressure sensitiveadhesive applied foil laminate surface, or other reflective layer suchas foil with radiation insulation properties. Alternatively, spray foaminsulation may be sprayed on the inner surface of the panels, ratherthan insulation panels being adhered or affixed thereto. In suchembodiments, air purification coating 144 may be disposed on an innersurface of insulation panels 142 and thus on an inner surface of theHVAC air conveyance apparatus 100 in contact with airflow through theinstalled air conveyance apparatus. In embodiments where insulationpanels 142 are not employed an air purification coating may be disposeddirectly on the inner surface of each panel 102, 104 and 106, of theplurality of panels forming the HVAC air conveyance apparatus, includingon an inner surface of door 118, in contact with airflow through theinstalled air conveyance apparatus. For example, Manganese dioxide, suchas in combination with Titanium dioxide, may be used to coat interiorsurfaces of air conveyance apparatus 100. Manganese dioxide exhibitsthermocatalytic activity for the decomposition of organic pollutants.Coupling Titanium dioxide with Manganese dioxide degrades organicsfurther than Titanium dioxide alone, due to the thermocatalytic activityof Manganese dioxide. Further, one or more of the panels (e.g., sidepanels 106) may include prefabricated (pilot) holes (not shown) whichallow an operator or installer to quickly mount an in-duct filter, airpurifier, germicidal (ultraviolet (IV)) lamp, disinfecting technology,or the like (not shown) in HVAC air conveyance apparatus 100. Theseprefabricated (pilot) holes may be accompanied by a “call out” that canbe a sticker (over the prefabricated (pilot) holes), metal engraving,laminate, painted, etc. (not shown).

With particular attention directed to FIGS. 3 and 5 , as noted, at leastone of the panels making up air conveyance apparatus (e.g., atransition) 100 may have an HVAC component access door 118. Figure Sshows end panel 104 with HVAC component access door 118.

Retaining latches 120 in FIG. 5 removably secure door 118 (closed) topanel door frame 122 of panel 104. As noted, door 118 may be fastened to(peripherical) door frame 122 of panel 104 by means of latches 120, suchas by each of latches 120 swiveling about a concentric point 146, on(insulated) door 118) a predetermined amount, such as generally aboutninety degrees. Door frame 122 may define door frame slots 148 forreceiving the jaw section 150 of latches 120. This door latchingmechanism may provide “stay-locked” features to combat pressurevariances that may otherwise cause door 118 to (unlatch and) open,unlike prior latches where there is minimal resiliency to forces thatmay cause the door latch to rotate to an open position when a load isapplied to the door, thus triggering the door to leak or freely openduring operation. When a positive internal pressure is applied withinair conveyance apparatus 100, torque is applied from door frame 122 tolatch (arm) 120 that causes it to rotate further into the “locking”direction (i.e., toward inside frame ledge 152). For example, inaccordance with embodiments, when assembled and installed conveyanceapparatus 100 is exposed to a positive internal pressure acting on theinside of door 118, the edge of the slot (148) in door frame 122 imposesa force onto the arm portion of latch 150. This tangential force actingon the latch arm (150) is a predetermined distance away from fastener146, thereby acting as a moment arm. The resulting torque therebyapplied to latch 120 causes the latch to be rotationally forced into itslocking, or securing, position inside of slot 148. This torque can beovercome by a human operator applying an opposing torque on the latch bymeans of the latch tab, thereby causing the latch to rotate into an“un-locked” position before servicing. Door 118, and frame 122, may besized such that removal of door 118, by release of laches 120, may, mayremove (almost) an entire face of assembled air conveyance apparatus100. Door 118 is fit to bottom out on inside ledge 152 of door frame 122so as to seal against leakage of air. The combined, or complementary,geometry of door 188, frame 122 and/or frame ledge 152 may enablecompression of insulation 142, such that the insulation acts as agasket, or enable a flush sheet metal on sheet metal edge between dooredge 154 and inside frame ledge 152.

In accordance with various embodiments of the present systems andmethods, panels 102, 104 and 106 may be prepared for shipment into thefield and eventual assembling into air conveyance apparatus (e.g., atransition) 100 by (alternately) stacking the pair of first,quadrilateral (end) panels 102 and 104 with the pair of secondquadrilateral (side) panels 106, in various configurations. Thereby,embodiments of the present field-assembled sheet metal air conveyanceapparatus save on shipping costs, particularly as compared to one piece,or fully assembled air conveyance apparatus. FIG. 9 is perspective viewof example doored end component panel 104 of FIG. 5 , one example sidecomponent panel 106 of FIG. 6 , example solid end component panel 104 ofFIG. 4 and another example side component panel 106 of FIG. 6 stackedfor shipment into the field for filed assembly of air conveyanceapparatus 100, according to some embodiments. Also, in accordance withvarious embodiments of the present systems and methods, panels 102, 104and 106 may be prepared for shipment into the field and eventualassembling into air conveyance apparatus 10) by stacking the panels withdoored end panel 104 and solid (back) end panel 102 are on the outsideof the stack with the (two) side panels 106 disposed between, such asillustrated in FIG. 10 .

FIG. 11 is flowchart of process 1100 for field-assembly of a sheet metalair conveyance apparatus (100) (and its use in an HVAC system (1000)),according to some embodiments. Initially, the panels (102, 104 and 106)to be used in the air conveyance apparatus (e.g., a transition) areunstacked and at 1105 a pair of first (end) quadrilateral panels (102and 104) are assembled to a pair of second (side) quadrilateral panels(106) to form a HVAC air conveyance apparatus (100). Assembly at 1105 iscarried out by, at 1110, inserting a right-angle flange (110) extending(inward) from each of a pair of opposite edges (112) of each of thefirst (end)quadrilateral panels (102 or 104) into a hemmed cleat (108)defined along each of a pair of opposite edges (124) of each of arespective one of the second (side) quadrilateral panels; 106. Then, at1115, each of the first quadrilateral (end) panels (102 and 104) issecured to the respective one of the second quadrilateral (side) panels(106) with a fastener (138) received through a pilot hole (136) definedthrough a projecting lip (132) of the hemmed cleat (108) of each of thesecond quadrilateral (end) panels into the right-angle flange (110)extending from the respective one of the first quadrilateral (side)panels. Securing the panels at 1115 may include, by way of examplereceiving the fastener (138) through the fastener receptive pilot hole(136) defined through the projecting lip (132) of the hemmed cleat (108)of each of the second quadrilateral (side) panels (106) into a screwreceptive pilot hole (140) defined in the right-angle flange (110)extending from the respective one of the first second quadrilateral(end) panels (102 or 104).

FIG. 12 is a perspective diagrammatic view of HVAC system 1200 employingan embodiment of the present field-assembled sheet metal air conveyanceapparatus (e.g., a transition) 100, according to some embodiments.Therein, HVAC system 1200 includes first HVAC unit 1205, which may be anair handling unit, such as a gas or electric furnace, or the like, andsecond HVAC unit 1210, which may be a set of cased air conditioningevaporator coils, or the like. An embodiment of the presentfield-assembled sheet metal HVAC air conveyance apparatus 100, such asdescribed above, is disposed between, and secured to, first HVAC unit1205 and second HVAC unit 1210. Alternatively, first HVAC unit 1205 maybe a set of cased air conditioning evaporator coils, or the like, andsecond HVAC unit 1210 may be an air handling unit, such as a gas orelectric furnace, or the like. An embodiment of the presentfield-assembled sheet metal HVAC air conveyance apparatus 100, such asdescribed above, is disposed between, and secured to, first HVAC unit1205 and second HVAC unit 1210. In various other embodiments, first unit1205 and second unit 1210 may be units to be tested in operationtogether and air conveyance apparatus 100 may act as an air conveyanceapparatus between units 1205 and 1210. Likewise, in a laboratorysetting, or the like, first unit 1205 and second unit 1210 may betesting units, research units, or the like, joined by air conveyanceapparatus 100 to act as an air conveyance apparatus between units 1205and 1210.

Returning to FIG. 11 , to assemble a HVAC system (1200) the assembledHVAC air conveyance apparatus (100) is disposed, at 1120, between afirst HVAC unit (1205) and a second HVAC unit (1210), with HVAC unitmating flanges 114 extending from each other opposite edge 116 of eachfirst and/or second quadrilateral panels (102 and 104, or 106) receivedsecurable by an open end of each of the first and second HVAC units(1205 and 1210). At 1125 the assembled HVAC air conveyance apparatus(100) is secured between the first HVAC unit (1205) and the second HVACunit (1210) using a plurality of fasteners (1215) through (a side of therespective HVAC unit and) the HVAC unit mating flanges (114). Inaccordance with various embodiments of the present systems and methods,the installer may also employ tape with the intentions of sealing andfurther adhering the air conveyance apparatus (100) in place to theadjacent/connected HVAC appliance (1205 and/or 1210). The installer,operator, or customer may also adhere tape within the inside of theunit(s) (1205 and/or 1210) and/or the air conveyance apparatus (100), inorder to further seal the air conveyance apparatus in-line withconnected HVAC components (1205 and/or 1210).

The order in which each operation of a given method is performed may bechanged, and various operations may be added, reordered, combined,omitted, modified, etc. It is intended that embodiment(s) describedherein embrace all such modifications and changes and, accordingly, theabove description should be regarded in an illustrative rather than arestrictive sense.

After assembly the combined components of the unit combine and yieldbenefits such as improved system efficiency, in that, the assembledsystem maintains SEER, air flow distribution, heating element exposure,and the like. Further, the combined component unit yield minimizedsystem resistance to the system(s), such as minimized turbulence,minimized minor dynamic pressure loss, minimized flow resistance.Improved service accessibility to the system(s) is also provided in thecombined component unit, including a large removable panel (door 118).The combined component unit further yields attenuated sound power ofsystem(s) during operation, so as to provide an increased SoundTransmission Class (STC), increased Noise Reduction Coefficient (NRC),and/or the like. The combined component unit also yields improvedresistance to fungi and/or bacteria growth between systems. For example,the combined component unit has low moisture absorption, and thus,eliminates harboring of potential biological life. Improved passive fireprotection of system(s) and the associated structure, in the combinedcomponent unit is non-combustible. The combined component unit furtherprovides reduced (risk of) chemical exposure and deposition throughoutthe system(s) and structure, in that certified insulation, or the like,used in the combined component unit is proven to reduce indoor airpollution, and the like.

Leak testing was conducted on an embodiment of the present airconveyance apparatus. The apparatus was assembled on site, as isintended to be done by an installer or operator at the scene ofinstallation, and then subjected to internal flow by fans that replicatetypical HVAC flow parameters. Using various instrumentation, volumetricflow rates were captured by testing facility provided vent hoods in sucha way that recorded air successfully channeled through the apparatus, aswell as air that escaped through the confines of the apparatus. Understeady state volumetric flow of 1600 cubic feet per minute, bothvolumetric flow rates of channeled air and leaked air were recordedsimultaneously. The following results were obtained: 7 CFM of leakageduring 1600 CFM of flow at an internal positive pressure of 0.23 incheswater column (W.C.); 14.5 CFM of leakage during 1600 CFM of flow at aninternal positive pressure of 0.51 inches W.C. and 32.25 CFM of leakageduring 1600 CFM of flow at an internal positive pressure of 1.27 inchesW.C. Thereby, sealing of the assembled air conveyance apparatus, asdescribed above was confirmed.

As discussed above, positioning an air tilter in an HVAC system at alocation abutting the base of an electric air handling unit places theair filter close to or adjacent the evaporator coil in the air handlingunit, which increases the static pressure in the HVAC system. FIG. 13illustrates a side perspective view of a heating, ventilation and airconditioning (HVAC) system 200 including an air conveyance apparatus(e.g., a transition) 100 that obviates the increase in static pressurecaused by conventional air filter placement. In some embodiments, theair conveyance apparatus (e.g., a transition) 100) may be formed of thepanels 102, 104, 106 discussed above, and may include any or all of theassociated features discussed above with respect to FIGS. 1 to 10 . Inother embodiments, the air conveyance apparatus (e.g., transition) 100may be a pre-fabricated transition with panels that are assembled at afactory (e.g., non-knockdown transition), such that the air conveyanceapparatus (e.g., transition) 100 is installed whole in the field. Asdescribed above, the air conveyance apparatus (e.g., transition) 100 maybe formed of at least four panels (e.g., 102, 104, 106) that togetherdefine a perimeter of the air conveyance apparatus (e.g., transition)100 and an interior thereof. The air conveyance apparatus (e.g.,transition) 100 may have a first end configured to be attached to anelectric air handler 202 as shown in FIG. 13 , and a second end oppositethe first end. The air conveyance apparatus (e.g., transition) 100 maybe attached to the electric air handler 202 via clips, snaps, screws,tape, adhesive, or other attaching devices.

As shown in FIG. 13 , the HVAC system 200 includes an electric airhandler 202. An evaporator coil (or a set of evaporator coils) 204, anair blower 206, and a heater (or furnace) 208 may be provided inside theelectric air handler 202. The evaporator coil (or set of evaporatorcoils) 204 may be any type of coil, and may include, for example, boxcoils or slab coils, either of which may be in an arrangement that ishorizontal, vertical, or a combination thereof. Example box coilsinclude multi-poise A-coils, performance A-coils, and N-coils. Theblower 206 may include a motor that forces heated or cooled air passingover the evaporator coil 204 through the ducts (not shown) of the HVACsystem 200, and out of vents in rooms throughout the house or buildinghaving the HVAC system 200. The heater (or furnace) 208 of the HVACsystem 200 may include components, such as an electric heating element,that heat air passing through the electric air handler 202 andcirculating through the HVAC system 200.

The HVAC system 200 also includes an air filter 210 that may removeimpurities such as dust, pet dander and/or bacteria from the air flowingthrough the HVAC system 200. The inventors of the present invention havediscovered that placing an air conveyance apparatus (e.g., a transition)100 between the air filter 210 and the electric air handler 202 cangreatly reduce or eliminate the static pressure that would otherwiseexist without a transition. The air conveyance apparatus (e.g., atransition) 100 can provide enough distance between the air filter 210and the evaporator coil 204 inside the electric air handler 202 tomaximize airflow entering the base of the electric air handler 202without a restriction, in some embodiments, the length of the airconveyance apparatus (e.g., a transition) 100 from a first end thereofthat abuts the electric air handler 202 to an opposite second end thatabuts the air filter 210 may be at least 8 inches, so that when the airconveyance apparatus (e.g., a transition) 100 is provided between theair filter 210 and the electric air handler 202 the air filter 210 is atleast 8 inches away from the electric air handler 202 and the evaporatorcoil 204 inside the electric air handler 202. This length of the airconveyance apparatus (e.g., a transition) 100 (or distance between theelectric air handler 202 and the air filter 210) may allow the airblower 206 to operate without any overworking. In some embodiments, thelength of the air conveyance apparatus (e.g., a transition) 100 from afirst end thereof to the opposite second end may be 8 inches to 9 inchesin order provide better air flow from the air filter 210 on the secondopposite end of the air conveyance apparatus (e.g., a transition) 100 tothe electric air handler 202 on the first end. However, the length ofthe of the air conveyance apparatus (e.g., a transition) 100 from afirst end thereof to the opposite second end may be greater than 9inches depending on the design and requirements of the HVAC system 200.

The air conveyance apparatus (e.g., a transition) 100 can be sized tothe dimensions of the electric air handler 202 and/or the air filter 210so that airflow between the air handler 202 and the air filter 210 canbe maximized and the static pressure minimized. Conversely, the airfilter 210 can be sized to match the dimensions of the air conveyanceapparatus (e.g., a transition) 100. For instance. FIG. 13 shows anembodiment in which the first end of the air conveyance apparatus (e.g.,a transition) 100 has a perimeter that is smaller than the perimeter ofthe second opposite end thereof, so that the perimeter of first end issized to match the dimension of the smaller opening of the electric airhandler 202. The larger perimeter of the second opposite end of the airconveyance apparatus (e.g., a transition) 100 matches the dimension ofthe larger perimeter of the air filter 210. Sizing these components tomatch or fit the dimensions of each other as described in the exampleabove can eliminate the offset between the air filter 210 and theelectric air handier 202, which would otherwise result in restricted airflow and thus increased static pressure. In some embodiments, the airconveyance apparatus (e.g., a transition) 100 may include the air filter210, such that the air filter 210 is a part of the air conveyanceapparatus (e.g., a transition) 100. In some of those embodiments, theair filter 210 may be a replaceable part of the air conveyance apparatus(e.g., a transition) 100. The air filter 210 may be attached to the airconveyance apparatus (e.g., transition) 100 via clips, snaps, screws,tape, adhesive, or other attaching devices.

FIG. 13 shows that the HVAC system 200 may also include an air returnunit 212 on a side of the air filter 210 that is opposite the side thatabuts the air conveyance apparatus (e.g., a transition) 100. The airreturn unit 212 may allow the air in the house or building having theHVAC system 200 to return to the system for continued heating orcooling.

In addition, one of the panels 104 of the air conveyance apparatus(e.g., a transition) 100 may include the removable access door 118discussed herein. The removable access door 118 may allow for accessinto the interior of the air conveyance apparatus (e.g., a transition)100 for cleaning and/or inspection of the evaporator coil 204 and/or theair filter 210 without having to disassemble the component parts of theHVAC system 200. Further, instruments that measure static pressure canbe inserted into the air conveyance apparatus (e.g., a transition) 100through the opening in the panel 104 provided by the removable accessdoor 118.

In some embodiments, one or more of the panels 102, 106 of the airconveyance apparatus (e.g., a transition) 100 may include one or moreaccess ports 214 opening into the interior of the air conveyanceapparatus (e.g., a transition) 100. The access ports 214 may bepre-punched holes of any kind. The access ports 214 may permit accessfor a variety of reasons, e.g., for installing and/or mounting of:static pressure measuring devices; air flow and air quality meteringdevices; and temperature and other types of probes or metering devicesfor testing temperature and other metrics within the HVAC system 200.The mounting may be accomplished, for example, by any fastening devicesknown or available. In addition, one or more of the panels 102, 106 ofthe air conveyance apparatus (e.g., a transition) 100 may include amounting port 216 opening into the interior of the air conveyanceapparatus (e.g., a transition) 100. The mounting port 216 may be apre-punched hole of any kind, and may permit access for and mounting ofan ultraviolet light and baffle assembly 218 within the interior of theair conveyance apparatus (e.g., a transition) 100. The mounting may beaccomplished, for example, by any fastening devices known or available.

FIG. 14A illustrates the main components of the ultraviolet light andbaffle assembly 218 according to an embodiment. In the embodiment, theultraviolet light and baffle assembly 218 includes an ultraviolet lightemitter 219 or other ultraviolet radiant tube device, and a baffle 220that is configured to be detachably attached to the ultraviolet lightemitter 219. The baffle 220 may be detachably attached to theultraviolet light emitter 219 via. e.g., clips 221 that grip ends orother portions of the ultraviolet light emitter 219. FIG. 14B is aperspective view of the baffle side of the assembled ultraviolet lightand baffle assembly 218. The baffle side is adapted to face the filter210 when mounted within the air conveyance apparatus (e.g., atransition) 100 to protect the air filter 210 from being degraded by theultraviolet light from the ultraviolet light emitter 219. Meanwhile, theultraviolet light from the ultraviolet light emitter 219 may eliminatemold and mildew, kill viruses and bacteria, and reduce odors, thusincreasing the efficiency of the HVAC system 200 and improving thequality of the indoor air in the HVAC system 200. FIG. 14C is aperspective view of the ultraviolet light side of the assembledultraviolet light and baffle assembly 218. The ultraviolet light side isadapted to face the evaporator coil(s) 204 of the electric air handler202 when mounted within the air conveyance apparatus (e.g., atransition) 100 to help clean the evaporator coil(s) 204 and air thatpasses through the HVAC system naturally.

While the embodiment of FIG. 13 shows the removable access door 118 on aside panel of the air conveyance apparatus (e.g., a transition) 100,FIG. 15 illustrates another embodiment of the HVAC system 200 in whichthe removable access door 118 on a top panel of the air conveyanceapparatus (e.g., a transition) 100. Other components of the HVAC system200 shown in FIG. 15 may be the same or similar as in the system shownand described herein with respect to FIG. 13 .

FIG. 16 is a diagrammatic view of a method 300 of transitioning withinan HVAC system 200 employing an air conveyance apparatus (e.g., atransition) 100 according to some embodiments. The method 300 may beginafter the field assembly process 1100 shown in FIG. 11 and describedabove has been completed. At step 302 of the method, a first opened endof the assembled air conveyance apparatus (e.g., a transition) 100 ispositioned at a first opened end of the electric air handler 202, whichair handler includes the evaporator coil(s) 204, the air blower 206, andthe heater (or furnace) 208 as discussed above. At step 304, a firstside of the air filter 210 discussed herein is positioned at a secondopened end of the air conveyance apparatus (e.g., a transition) 100, thesecond opened end being opposite the first opened end of the airconveyance apparatus (e.g., a transition) 100. The air filter 210 may bepositioned at the second opened end of the air conveyance apparatus(e.g., a transition) 100 to be at least 8 inches away from the airhandler 202 as discussed herein. As also discussed herein, one of thepanels 104 of the air conveyance apparatus (e.g., a transition) 100 maybe provided with the removable access door 118 that opens to allowaccess into the interior of the air conveyance apparatus (e.g., atransition) 100. In addition, one of the panels 102, 206 of the airconveyance apparatus (e.g., a transition) 100 may be provided with oneor more access ports 214 opening into the interior of air conveyanceapparatus (e.g., a transition) 100. At step 306, an opened end of theair return unit 212 may be positioned on a second side of the air filter210, the second side being opposite the first side of the air filter210. At step 308, an ultraviolet light and baffle assembly 218 may bemounted within the air conveyance apparatus (e.g., a transition) 100. Abaffle 220 may be positioned on the ultraviolet light 219 to face theair filter 210 to protect the air filter 210 from being degraded byultraviolet light.

Although the present invention and its advantages have been described indetail, it should be understood that various changes, substitutions andalterations can be made herein without departing from the spirit andscope of the invention as defined by the appended claims. Moreover, thescope of the present application is not intended to be limited to theparticular embodiments of the process, machine, manufacture, compositionof matter, means, methods and steps described in the specification. Asone of ordinary skill in the art will readily appreciate from thedisclosure of the present invention, processes, machines, manufacture,compositions of matter, means, methods, or steps, presently existing orlater to be developed that perform substantially the same function orachieve substantially the same result as the corresponding embodimentsdescribed herein may be utilized according to the present invention.Accordingly, the appended claims are intended to include within theirscope such processes, machines, manufacture, compositions of matter,means, methods, or steps.

What is claimed is:
 1. An air conditioning system comprising: an airhandler; an evaporator coil in the air handler; a blower in the airhandler; a heater in the air handler; an air filter; and a transitionbetween the air handler and the air filter.
 2. The air conditioningsystem according to claim 1, further comprising: an air return unit onone side of the air filter.
 3. The air conditioning system according toclaim 1, wherein the transition comprises a panel that includes anaccess door that opens to allow access into an interior of thetransition.
 4. The air conditioning system according to claim 1, whereina length of the transition is at least 8 inches so that the air filteris at least 8 inches away from the air handler.
 5. The air conditioningsystem according to claim 1, wherein the transition includes a panelcomprising one or more access ports opening into the interior of thetransition.
 6. The air conditioning system according to claim 1, furthercomprising: an ultraviolet light mounted within the transition; and abaffle on the ultraviolet light, wherein the baffle is positioned toface the air filter to protect the air filter from being degraded byultraviolet light.
 7. A transition for an air conditioning system, thetransition comprising: at least four panels that together define aperimeter of the transition and an interior of the transition; a firstend configured to be attached to an air handler; a second end oppositethe first end; and an air filter at the second end, wherein at least oneof the at least four panels includes an access door that opens to allowaccess into the interior of the transition.
 8. The transition accordingto claim 7, wherein a length of the transition from the first end to thesecond end is at least 8 inches.
 9. The transition according to claim 7,wherein at least one of the at least four panels includes one or moreaccess ports opening into the interior of the transition.
 10. Thetransition according to claim 7, wherein the at least four panels areconfigured to be detachably attached to each other to allow thetransition to be field assembled at a job site.
 11. The transitionaccording to claim 7, wherein wherein at least one of the at least fourpanels includes a mounting port for mounting an ultraviolet light andbaffle within the interior of the transition.
 12. A method oftransitioning within an air conditioning system, the method comprising:positioning a first opened end of a transition at a first opened end ofan air handler comprising an evaporator coil, a blower, and a heater;and positioning a first side of an air filter at a second opened end ofthe transition, the second opened end being opposite the first openedend of the transition.
 13. The method according to claim 12, furthercomprising: positioning an opened end of an air return unit on a secondside of the air filter, the second side being opposite the first side.14. The method according to claim 12, further comprising: providing apanel of the transition with an access door that opens to allow accessinto an interior of the transition.
 15. The method according to claim12, wherein the air filter is positioned at the second opened end of thetransition to be at least 8 inches away from the air handler.
 16. Themethod according to claim 12, further comprising: providing a panel ofthe transition with one or more access ports opening into the interiorof the transition.
 17. The method according to claim 12, furthercomprising: mounting an ultraviolet light within the transition, whereina baffle is positioned on the ultraviolet light to face the air filterto protect the air filter from being degraded by ultraviolet light.